Apparatus for fabricating connectors



J. A. BADINI ET L APPARATUS FOR FABRICATING CONNECTORS June 24, 1969Sheet Filed March 20, 1967 m gm 55$ \QQ lllllilsrlillll Iv VENTURE 4.1.HEHD/N/ gas/ E Jq.

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O e I III- June 24, BAD N ET AL 3,451,118

APPARATUS FOR FABRICATING CONNECTORS Filed March 20, 1967 Sheet 5 of 5June 24, 1969 .1. A. BADINI ET APPARATUS FOR FABRICATING CONNECTORSFiled March 20, 1967 WHE June 24, 1969 J. D N ET AL 3,451,118

APPARATUS FOR FABRICATING CONNECTORS Filed March 20, 1967 Sheet 5 of 5United States Patent 3 451,118 APPARATUS FOR FAliRICATING CONNECTORSJohn A. Badini, Bronx, N.Y., and Walter R. Scherb, Jr.,

Bridgewater Township, Somerset County, N.J., assignors to WesternElectric Company, Incorporated, New

York, N .Y., a corporation of New York Filed Mar. 20, 1967, Ser. No.624,260

Int. Cl. H01r 43/ 00 US. Cl. 29--203 8 Claims ABSTRACT OF THE DISCLOSUREA fabricating apparatus includes a first station which both produces asegment of a wire conductor having a predetermined length and bends suchsegment into a U-shape, the connecting portion of the U having a lengthsubstantially equal to the distance between a pair of holes in anarticle. A second station of the apparatus next inserts the U-shapedsegment into the holes with the ends "of the segment protruding beyondthe article, and finally forms sequentially the protruding segment endsto clinch the segment to the article and to extend one of the protrudingends beyond the periphery of the article. The apparatus includes ashuttle selectively movable between the first and second stations, whichshuttle comprises facilities for aiding in the bending, inserting andforming of the segment.

BACKGROUND OF THE INVENTION Field of the invention This inventionrelates to apparatus for fabricating connectors and particularly toapparatus for fabricating and attaching a connector made of wire to afirst electrical device, the connector being usable to effect both amechanical and electrical union between the first device and a seconddevice.

Description of the prior art In the manufacture of electrical equipmentit is often necessary to join together electrical devices. Certain typesof electrical devices, such as printed circuit boards associated witheach other in constructing modular-like systems, are utilized forreasons of economy, of space, and of mechanical rigidity.

To assure manufacturing economy both in time and cost, a new type ofconnector has been designed. The new connector is fully described inapplication Ser. No. 601,079, filed Dec. 12, 1966. Briefly, suchapplication describes a connector particularly useful in effectingelectrical and mechanical union between electrical devices. Theconnector comprises an originally straight segment of relatively heavygauge conductor. The straight segment, after first being produced from asupply of stock, is bent into a U-shape, the base or connecting portionof the U having a length substantially equal to the distance between apair of holes formed in a first electrical device. The ends of theU-shaped segment are inserted respectively into the holes until theyprotrude beyond the first device. The protruding ends are then formedboth to clinch the segment to, and to extend one of the ends beyond, theperiphery of such device. The one extending end may then be affixed to asecond device to serve both as a mounting post for the first device andas an electrical connector between the devices.

It is usually advantageous to attach a plurality of the above-describedconnectors to the first device to effect electrical and mechanical unionbetween the devices at a plurality of points. While the attachment ofthe plural connectors to the first device may be effected one-at-a-timePatented June 24, 1969 by hand, it is obviously advantageous toaccomplish such attachment simultaneously in an automatic fabricatingapparatus. Such an automatic apparatus both assures the continuedeconomy of the already economical connector and assures uniformity ofthe end product. No prior art machines are known which are suitable forforming and attaching connectors of the type being considered.

SUMMARY OF THE INVENTION Accordingly, an object of this invention istoprovide a new and improved apparatus for fabricating connectors.

Another object of this invention resides in the provision of new andimproved apparatus for fabricating and attaching a connector made ofwire to a first electrical device, which connector is usable to effectboth a mechanical and electrical union between the first device and asecond device.

Further, another object of the present invention is the provision of anautomatic apparatus for fabricating a connector wherein a conductorsegment is clinched to an article so that one end of the segmentprotrudes beyond the periphery of the article, the protruding endserving as the connector.

A further object of the present invention is to provide an automaticapparatus which fabricates a connector by bending a conductor segmentinto a U-shape, inserting the ends of the bent segment respectively intoholes in an article, and then forming sequentially the ends of the bentsegment both to clinch the segment to the article and to extend one ofthe ends beyond the periphery of the article, the protruding end servingas the connector.

Yet, another object of this invention resides in the provision of anautomatic apparatus for fabricating simultaneously a plurality ofelectrical connectors from wire stock and for attaching simultaneouslysuch connectors to an article.

With these and other objects in view, the present invention contemplatesa new and improved apparatus for fabricating wire connectors. Theapparatus includes a first station whereat a feeding and a cuttinginstrumentality produce, from wire stock, one or more wire segmentshaving predetermined lengths. A shaping or bending facility at the firststation bends the wire segments into U-shapes, the connecting portionsof the Us having lengths equal to the distance between respective pairsof holes in a first article. At a second station an insertion facilitythen inserts the respective ends of the bent segments into the holes ofrespective hole pairs so that the ends protrude beyond the article andso that the connecting portions of the Us are adjacent to the article.Lastly, a forming facility at the second station sequen-, tially formsthe protruding segment ends both to clinch the bent segments to thearticle and to extend one of the protruding ends of each of the segmentsbeyond the periphery of the article. Such extending ends are usable toeffect both electrical and mechanical union between the first articleand a second article at a plurality of points.

The fabricating apparatus includes a shuttle which is reciprocableselectively between the first station and the second station. Theshuttle includes facilities which aid in both the bending of thesegments into the U-shape and the retaining of such U-shaped segments asthe shuttle moves to the second station. The shuttle also includesfacilities for inserting the ends of the retained, U-shaped segmentsinto the holes of the article at the second station and for aiding theforming facility in clinching the segments to the article.

BRIEF DESCRIPTION OF THE DRAWINGS Other objects and advantages of thepresent invention will appear upon consideration of the followingdetailed description in conjunction with the accompanying drawingswherein:

FIG. 1 is a generalized flow chart depicting the stepby-step fabricationof a connector from wire stock and the attachment of such connector toan electrical device as performed by the apparatus of the presentinvention;

FIG. 2 is a side, elevational view of the apparatus of the presentinvention showing a second wire inserting and sequential forming stationand also a feeding device which feeds wire into a first bending station;

FIG. 3 is a front, elevational view taken along line 33 of FIG. 2depicting apparatus of the present invention and showing the first wirebending station and the second wire inserting and sequential formingstation;

FIG. 4 is a side, elevational, enlarged view of the feeding device ofFIG. 2;

FIG. 5 is a side, elevational, enlarged view of the first bendingstation taken along line 55 of FIG. 3;

FIG. 6 is an enlarged, elevational, side view of the second 'wireinserting and sequential forming station taken along line 6-6 of FIG. 3;

FIG. 7 is an enlarged view of that portion of FIG. 6 whereat theconnector is attached to the article as shown in the flow chart of FIG.1;

FIG. 8 is a perspective view of a printed circuit board having aplurality of connectors attached thereto by the apparatus of FIGS. 2-7;and

FIG. 9 is a sectional view along line 9--9' of FIG. 8 showing in greaterdetail one of the connectors produced by the apparatus of the presentinvention.

DETAILED DESCRIPTION Structure Attention is first directed to FIG. 1where there is shown a flow chart depicting the fabrication, from wirestock 10, of a connector 11 and the attachment of such connector to anelectrical article 12.

For convenience, a plurality of connectors 11 may be fabricated andattached simultaneously to the article 12 (as shown in FIG. 8), and tothis end a plurality of rotatably mounted supply reels 13 are showncorresponding to the number of connectors to be fabricated. The wirestock is pulled from the supply reels 13 by a wire stock feeder 14 (tobe described below) over a series of guide reels 15, 16, 17, and 18 andis fed into a first station 19.

At the first station 19 wire segments 20a (a leading edge of one ofwhich is shown) are separated from the stock 10. The segments 20a arethen each bent into a segment or staple having a U-shape 20b and havingends 21 and a connecting portion 22. The lengths of the connectingportions 22 are equal to the respective distances between pairs ofholes. 23 and 24 which have been previously formed through the article12 by apparatus not constituting a part of the present invention.

The Ushaped segments 20b are next moved to a second inserting andsequential forming station 27. At the second station 27, the ends 21 ofeach U-shaped segment 20b are inserted respectively into the holes 23and 24 of the respective hole pairs until the connecting portions I 22are adjacent to, but preferably spaced from, the surface of the article12. During such insertion, the ends 21 are partially formed away fromthe central axis of the holes 23 and 24 by a segment end forming shoe28. Preferably, the ends 21 are formed in diametrically oppositedirections.

A final former 29 then clinches the U-shaped and partially formedsegments 20b to the article 12 by completely forming the segment ends 21against the surface of the article 12. The partial forming of thesegment ends 21 by the shoe 28 followed by the complete forming of suchends 21 by the final former 29 is referred to hereinafter as sequentialforming because the ends are formed in a sequence and not all at once.Such clinching also extends one of the protruding ends 21 of each of thesegments 20b beyond the periphery of the article 12. Such extending ends21 may ultimately serve as connectors for effecting electrical andmechanical union between the article 12 and another electrical article30 at a plurality of points.

Exemplary of the type of electrical article 12 to which one or more ofthe connectors 11 may be attached, is a printed circuit board 31, asshown in FIGS. 8 and 9. The holes 23 and 24 are preferably formedthrough such board 31 in pairs, each pair being located on a line whichis perpendicular to a selected edge 32 of the board 31. Additionally,the holes 23 and 24 may be formed within and through circuit paths 33 onthe board 31.

Referring to FIGS. 1, 8 and 9, the extending ends 21 of the segments 20bof the connectors 11 may all extend beyond the board edge 32 by the sameamount. For convenience, however, the extending ends 21 of the extremeright and left-hand connectors 11 extend beyond the edge 32 more thanthe other ends 21, as shown in FIG. 8. In any event, the extending ends21 are sufficiently long to be inserted into apertures 34 formed throughselected portions of both a master printed circuit board 35 and circuitpaths 36 thereon.

Underlying the connecting portions 22 of the clinched, U-shaped segments20b may be terminations 37 of the circuit paths 33 on the board 31 (FIG.9). Also attached in the usual manner to both boards 31 and 35 are leads38 of electrical components 39.

After the U-shaped segments 20b have been clinched to the board 31 andthe leads 38 have been attached, the entire board 31 may be soldered.Such soldering produces strong and reliable electrical connectionsbetween the segment connecting portions 22 and the underlyingterminations 37 due to molten solder 40 being pulled into a space 41therebetween by capillary action (FIG. 9).

Referring to FIGS. 2 and 3, apparatus 42 for fabricating the connector11, as described above, is shown to include a horizontal table 43 and avertical base 44 mounted to the table 43. Below the table 43 is a cage45 within which are contained the supply reel 13 and the guide reels 15and 16. Such reels 13, 15 and 16 may be rotatably supported in anydesired manner, a grid of struts 46 and a bracket 47 being shown forconvenience.

At the front of the cage 45 is an outlet 48 through which the wire stock10 issues and then travels over the guide reels 17 and 18 to the feeder14. The guide reels are rotatably mounted to pairs of brackets 49 and 50which are fastened respectively to the table 43 and to an erect,L-shaped prop 51 which is also fastened to the table 43.

Referring now to FIGS. 2 and 4, at the feeder 14, the wire stock 10enters a slotted guide plate 52. The guide plate 52 is mounted to theupright portion of the prop 51. A movable feed block 53 is reciprocablebetween the crook of the L-shaped prop 51 and a vertical column 54 alonga guide rod 55. The feed block 53 is reciprocated parallel to the majoraxis of the Wire stock 10 by a piston rod 57 of a selectivelypressurized piston-cylinder 58 (FIG. 3). The piston rod 56 may beconnected to the feed block 53 by any desirable means, a rigiddoubletongue 59 being shown for convenience.

The feed block 53 contains a plurality of feed pawls 60 swingablymounted within a cutout 61 of the feed block 53 on a common pintle 62which both runs the entire width of the feed block 53 and is fastened tothe outer walls thereof. The number of the pawls 60 corresponds to thenumber of lengths of wire stock 10 to be used.

The wire stock 10 enters and passes through the feed block 53 at thebottom of the cutout 61 therein from a similar cutout 63 in the prop 51.

As viewed in FIG. 4, the feed pawls 60 are rotatively biased in aclockwise direction by a spring 64 attached to the block 53 by a springmount 65. During rightward movement of the feed block 53 a gripping edge67 on the lower end of each pawl 60 engages and digs into the wire stock10 thereunder due to the biasing action of the spring 64. Such rightwardmotion of the feed block 53, therefore, feeds the wire stock rightwardlythrough guide passages 68 in the column 54 and into the first station 19which is to the right of such column 54, as viewed in FIG. 4. Therightward motion of the feed block 53 may ultimately be stopped eitherby appropriate depressurization of the piston-cylinder 58 or by theabutment of a collar 69, which is concentric with piston rod 58, againstthe column 54.

Leftward motion of the feed block 53 slides the gripping edge 67 of thefeed pawls 60 over the wire stock 10 in a non-engaging manner. Duringsuch leftward motion of the feed block 53, the wire stock 10 isprevented from being pushed leftwardly by engagement with gripping edges70 of stop pawls 71 swingably mounted on a common pintle 72 within thecutout 63 in the prop 51. The stop pawls 70 are biased in a clockwisedirection by springs 73 inserted through the front of the prop 51 andmaintained against the pawls 70 by set screws 74 threaded through thetop of such prop 51. The gripping edges 70 of the stop pawls 71 permitthe wire stock 10 to slide freely thereunder during the rightwardmovement of the feed block 53.

In the extreme rightward position of the feed block 63 a lobe 79 thereoncontacts the operating arm 80 of a microswitch 81 mounted to the column54. Such switch 81 operates certain facilities at the first station 19and may also depressurize the piston-cylinder 58 to return the feedblock 53 to its extreme leftward position.

Leftward movement of the feed block 53 is limited by an extension 82 ofthe double tongue 59, which extension 82 is positioned between the feedblock 53 and the prop 51. In the extreme leftward position, feed pawlreset cams 83, mounted to the prop 51, enter the cutout 63 of the feedblock 53 and contact the feed pawls 60. Such contact rotates slightly ina counterclockwise direction the feed pawls 60 against the action of thespring 64 to raise the gripping edges 67 of the pawls 60 out ofengagement with the wire stock 10. Thus, some slight rightward movementof the feed block 53 may be necessary before the spring 64 can urge thegripping edges 67 into feeding engagement with the wire stock 10. Therespective lengths of the reset cams 83 are adjustable to selectivelyvary the amount of rightward movement of the feed block 53 required toengage the wire stock 10 with the gripping edges 67. Thus, the amount ofwire stock 10 fed by each of the pawls 60 is selectively variable. Inthe present instance wherein the extending end 21 of the left andright-hand connectors 11 on the board 31 are longer than the remainderof the extending edges 21, the two feed pawls 60 at the right andleft-hand of the feed block 53 (as viewed in FIG. 3, unlike theremainder of the feed pawls 60, are conveniently already in feedingengagement with the wire stock 10 at the extreme leftward position ofthe feed block 53.

Thus, appropriate adjustment of the reset cams 83 and pressurization ofthe piston-cylinder 58 permits the feeder 14 to feed a predeterminedlength of the wire stock 10 into the first station 19.

Referring now to FIGS. 3 and 5, the first station 19 is seen to includean entrance 84, a cutter 87, and a bender or staple shaper 88. Alsopositioned within the first station 19 during the portion of the cycleof operation of the apparatus 42 to be described with respect to FIG. 5,is a reciprocable shuttle 90.

The entrance 84 of the first station 19 includes a wire stock guidepedestal 91, the top of which is a first rectangular body 92 having aplurality of apertures 93 to accommodate the movement therethrough ofthe wire stock 10 from the feeder 14. The bottom of the pedestal 91 is asecond rectangular body 94 having a slanted surface or discharge chute95 formed at the top thereof. The chute 95 slants downwardly toward thefeeder 14.

The cuttter 87 comprises a blade 96 positioned directly over the path ofthe wire stock 10 as the stock is fed to the entrance 84 by the feeder14. The blade depends from a driver 97 connected to an extension 98 of apiston rod 99. The piston rod 99 is movable vertically by a selectivelypressurized piston-cylinder 100. The driver 97 is journalled in a pairof ways 101 mounted to the vertical base 44. Vertical movement of suchdriver 97 is limited by a pin 102 firmly attached to the vertical base44 and positioned within a slot 103 formed in the driver 97.

In vertical alignment with the blade 96 is a groove 104 directly overwhich is the path taken by the wire stock 10 fed by the feeder 14. Thegroove 104 is formed in the guide pedestal 91 at the back of the firstbody 92 and communicates with the initial portion of the discharge chute95. Cutting edges 105 and 106 are provided at the back and frontrespectively of the groove 104. Selective pressurization of thepiston-cylinder i moves the blade into and out of the groove 104' pastthe cutting edges and 106.

As the feeder 14 feeds predetermined lengths of the wire stock 10 intothe first station 19, the microswitch 81 is operated by the lobe 79 onthe feed block 53. Such operation pressurizes the piston-cylinder 100 tomove downwardly the blade 96 into the groove 104. Downward movement ofthe blade 96 contacts the wire stock 10 therewith to cut such wire stock10 against the cutting edges 105 and 106. This cutting removes a smallslug 108 from the wire stock 10. The slug falls by gravity through thegroove 104 onto the slanted surface or discharge chute 95. From thechute 95 the slug 108 exits into a scrap metal container (not shown).The cutting of the wire stock 10, as described, produces a plurality ofstraight wire segments 20a which now rest within the first station 19.

As mentioned previously, the first station 19* at this time includes thereciprocable shuttle 90. The shuttle 90 is substantially vertical andterminates at the bottom thereof in a pair of flanges 111. The flanges111 are slidably held by a bearing surface 112 which facilitatesreciprocation of the shuttle 90 between the first station 19 and thesecond station 27. The bearing surface 112 is fastened to the table 43.

Formed completely through the shuttle 90 is a vertical passageway 113.Positioned within the passageway :113 is a slide 114 vertically movabletherein. Mounted to the top of the slide 114 are a plurality of stapleforming and driving fingers 117. One finger 117 is provided for each ofthe straight wire segments 20a and, therefore, for each of theconnectors 11 to be fabricated. The top surface of each finger 117normally is inserted slightly into and at the bottom of one of aplurality of staple shaping and retaining recesses or female dies 118within the shuttle 90, all of which recesses communicate with the firstpassageway 113.

At the first station 19 the fingers 117 are prevented from movingvertically due to the engagement of the slide 114 with the top of thebearing surface 112 on the table 43, as shown in FIG. 5. Moreover, afterthe operation of the feeder 14 and the cutter 87 one wire segment 20aoverlies each of the recesses 118 in the shuttle 90 The staple shaper 88includes a horizontal serrated plate 119 having a plurality of gaps 121formed in the periphery thereof. Each gap 121 overlies one of the stapleshaping recesses 118. Each wire segment 20a is positioned within one ofthe gaps 121, the side walls thereof preventing lateral movement of thesegment 20a and the back wall thereof preventing longitudinal movementof such segments 20a. The plate 119 is fastened to a vertical supportblock 122 which is in turn mounted to the table 43.

The staple shaper 88 also includes a plurality of downwardly extendingfingers or male die members 123 which are mounted to the extension 82 ofthe piston rod 99 behind the blade 96. The fingers 123 are in verticalalignment with respective ones of the recesses 118. Also mounted to theextension 82 is a positioning pin 124. Such pin has a truncated conicalend 127 in vertical alignment with positioning bore 128- formedcontinuously in the shuttle 90 and the plate 119.

The stapler shaper 88 further includes a plate-like staple retainer 129.The retainer 129 is horizontally disposed and has at one end thereof aplurality of downwardly extending shoulders 130. Each of the shoulders130 is aligned with and respectively insertable into one of the gaps1'21 between the serrations of the plate 119 and also overhangs one ofthe recesses 118 by an amount equal to the thickness of the wiresegments 20a.

The retainer 129 is vertically movable by the selective pressurizationof a piston-cylinder 131. Such piston-cylinder 131 drives a piston rod132 which is connected to a central portion of the retainer 129", thepiston rod 132 being vertically movable within a bore 133 in the supportblock 122. Downward movement of the retainer 129' is limited by abutmentof the bottom surface thereof with the top surface of the plate 119. Theretainer 129' also ex tends rearwardly through a cutaway 134 formed inthe vertical base 44.

Full downward movement of the extension 98 and of the retainer 129operates microswitches 137 and 138, respectively. The microswitch 137 isoperated by the rear portion of the driver 97 which contacts anoperating member 140 of the switch 137. The microswitch 138 is operatedby the rear portion of the retainer 129 which contacts an operatingmember 142 of the switch 138.

Operation of the microswitch 137 by downward movement of the driver 97permits pressurization of the pistoncylinder 131 to move the retainer129 downwardly and then permits depressurization of the piston-cylinder100 to move the driver 97 upwardly.

After one or more pieces of the wire stock have been inserted by thefeeder 14 into the first station 19 through the gaps 121 of the plate119 and over the staple shaping and retaining recesses 11-8, thepiston-cylinder 100 is pressurized by operation of the microswitch 81both to sever the wire stock 10, thus producing the wire segments a, asdescribed above and to move the fingers 123 against such segments 20a.The fingers 123 push the wire segments 20a into the staple shapingrecesses 118 to produce the U-shaped segments 20!).

Concurrent with the forming of the U-shaped segments 20b, thepositioning pin 124 enters the positioning bore 128 in the shuttle 90 toinsure proper alignment of the staple shaping recesses 118 with thefingers 123.

The retainer 129 is then moved downwardly as described above.Simultaneously with the removal of the fingers 123 from the stapleshaping recesses 118 due to operation of the microswitch 138 by theretainer 129, the shoulders 130 of the retainer 129 enter the gaps 121in the plate 119. The overhanging portions of such shoulders 130 contactone of the ends 21 of each of the U- shaped wire segments 20b to retainsuch segments 20b within the stable shaping recesses 118.

The retainer 129 is then moved upwardly in response to the operation ofthe microswitch 138. Such upward movement of the retainer 129 releasesthe microswitch 138 to actuate apparatus 147 for moving the shuttle 90to the second station 27.

The shuttle moving apparatus 147 includes a selectively pressurizedpiston-cylinder 148 connected to the shuttle 90 by a piston rod 149. Thepiston-cylinder 148 is mounted to the table 43 by a bracket 150 (seeFIG. 3).

Referring now to FIGS. 3 and 6, the second station 27 is seen to includea slide driving device 151, a printed circuit board clamp 152, and asequential former 153.

When the shuttle 90 is located at the second station 27, the bottomsurface of the slide 114 rests on an upward projection 154 of a pusher157, both of which comprise elements of the slide driving device 151.

The slide driving device 151 includes a hollow mounting member and guide158 affixed to the table 43- within a groove 159 formed within suchtable. Both the slide 114 and the upward projection 154 of the pusher157 are vertically aligned with the groove 159.

A cam 160 mounted to the end of a piston rod 161 of a selectivelypressurizable piston-cylinder 162 is movable from left to right (asviewed in FIG. 3) within the hollowed-out portion of the mounting member158. The cam 160 includes a cam surface 164 which continually engages acam follower 167 rotatably mounted to the bottom of the pusher 157. Suchcontinual engagement is effected by the tension force of a pair ofsprings 168 mounted to either end of a pair of pins 169 and 170. The pin169 is slidable within grooves 171 formed in the front and back of themounting member 158 and is also afiixed to the pusher 157. The pin isaffixed to the bottom of the mounting member 158.

Pressurization of the piston-cylinder 162 moves the piston rod 161rightwardly to engage the cam follower 167 with an upwardly slopingportion 172 of the cam surface 164. Such engagement moves the camfollower 167, the pusher 157, the upward projection 154, the slide 114,and finally the fingers 117 upwardly. Upward movement of the fingers 117moves the U-shaped segments 20b upwardly out of the staple shapingrecesses 118 in the shuttle 90.

The printed circuit board clamp 152 includes a slotted plate 173vertically movable on a pin 174 inserted into and apperture 177 in theplate 173. The pin 174 is mounted to an anvil support 178 which ismounted in turn to the table 43.

The plate 173 is biased to a normal upward position by a spring 179which is attached to the plate 173 and to a projecting support portion180 of the vertical base 44.

A bar 181 is rotatably mounted to the support portion 180 by a shaft182. At the lower end of the bar 181 is an elongated, rotatably mountedroller 183. Such roller 183 is movable against the force of the spring179 to contact the plate 173 upon counterclockwise rotation (FIG. 6) ofthe shaft 182. Such rotation of the shaft 182 may be effected eitherautomatically by a source (not shown) of motive power in response to theinsertion, either manually or automatically, of a board 31 into thesecond station 27 or by the manual rotation of a crank 184 attached tothe shaft 182.

Ineither case, contact of the plate 173 by the roller 183 moves suchplate 173 downwardly against the board 31 and against an anvil 187 whichis fixed to the anvil support 178. Such anvil 187 has a thicknessslightly greater than the thickness of the board 31 to prevent crushingof the board 31 by the plate 173. Moreover, the anvil 187 overhangs andpartially closes a passageway 188 defined by the anvil support 178 and aboard support 189. The passageway 188 accommodates the shuttle 90 whenthe shuttle is moved to the second station 27. The bearings 112 alongwhich the flanges 111 of the shuttle 90 move extend into the bottom ofthe passageway 188. Moreover, the groove 159 in the table 43 and theprojection 154 of the pusher 157 are aligned with the passageway 188 forelfecting upward movement of the fingers 117, as described above.

The plate 173 has a plurality of slots 190 therein similar to the gaps121 in the plate 119 at the first station 19. Each slot 190 isvertically aligned with one of the staple shaping recesses 118 when theshuttle 90 is moved to the second station 27.

Downward movement of the plate 173 clamps the board 31 against the boardsupport 189. Such clamping is limited, however, by the contact of theplate 173 with the anvil 187.

To properly locate the board 31 at the second station 27 so that eachpair of holes 23 and 24 is respectively aligned with the ends 21 of oneof the U-shaped wire segments 20b in the staple shaping recesses 118, aplurality of locating pins 191 are mounted to the board support 189.Such pins 191 fit within locating holes 192 formed in the board 31 (seeFIGS. 6 and 8).

The sequential former 153 comprises a plurality of the pre-forming shoes28 and the final former 29.

The shoes 28 are each located within one of the slots 9 190 in the plate173. Such shoes 28 include a surface 197 generally parallel with thesurface of the board 31 clamped at the second station 27 and a pair ofupwardly slanted surfaces 198 at the ends of the surface 197 in thegeneral configuration of a truncated triangle (FIG. 7).

When the plate 173 has been moved downwardly to the clamping position,the surfaces 197 of the members 193 contact the surface of the board 31,the ends of such surfaces 197 being immediately adjacent and betweenrespective ones of pairs of holes 23 and 24. Moreover, the slantedsurfaces 198 are positioned directly over such holes 23 and 24.

The final former 29 includes a plurality of downwardly extendingclinchers 199 equal in number to the number of slots 190 in the plate173. The clinchers 199 are movable into the slots 190 upon downwardmovement thereof. The clinchers 199 are all contiguous with a driver 200which is vertically slidable in ways 201 fastened to the vertical base44 and is connected to an extension 202 of a piston rod 203 of apiston-cylinder 204 (see FIG. 2). Movement of the driver 200 is limitedby the contact of the end of a groove 205 therein by a pin 206 mountedto the vertical base 44. Selective pressurization of the pistoncylinder204 is controlled by a microswitch 207 (FIG. 3) operated by therightward movement of the cam 160.

Each of the clinchers 199 includes at the lower end thereof a pair ofhammers 208. The hammers 208 are downward projections of the clinchers194 separated by a space 209 therebetween. The space 209 is equal to thewidth of and is aligned with the preforming shoes 28. Each hammer 208has a horizontal clinching surface 210 slightly offset fro-m the holes23 and 24 of the clamped board 31, as shown in FIG. 7.

Downward movement of the piston rod 203 by pressurization of thepiston-cylinder 204 moves each pair of hammers 208 into its underlyingslot 190 down past the shoes 28 which enter the space 209. This downwardmovement continues until the clinching surfaces 210 of the hammers 208are adjacent to but spaced from the board 31. I

After the shuttle 90 has been moved to the second station 27 by thepiston-cylinder 148, which is pressurized by the release of themicroswitch 138, a board 31 is clamped by the board clamp 152. Suchclamping positions each hole 23 and 24 of the hole pairs over one of theends 21 of respective ones of the U-shaped segments 20b held in therecesses 118 in the shuttle 90. Either the clamping of the board, or theactuation of a start button 211 after such clamping, pressurizes thepiston-cylinder 162. Pressurization of the piston-cylinder 162 moves thetop surface of the fingers 117 against the connecting portions 22 of theU-shaped segments 20b. Such movement of the fin-. gers 117 drives theU-shaped segments 20b out of the recesses 118, and pushes the ends 21thereof respectively into holes 23 and 24. The movement of the fingers117 continues until the connecting portions 22 of the U-shaped segments20b abut the surface of the board 31 between the holes 24 as seen inFIGS. 1 and 7. Alternatively, movement of the fingers 117 may be stoppedWhen the connecting portion 22 is slightly away from the board 31 todefine the space 41 (see FIG. 9).

Such continued movement of the fingers 117 also extends the segment ends21 beyond the upper side of the board 31. This extension forces the ends21 against the slanted surfaces 198 of the shoes 193 to pre-form thesegments 20b into an expanded U, as seen in FIG. 7. At this time, theends 21 are maintained in a proper vertical attitude by the slots 190 inthe plate 173. Moreover, such continued movement of the fingers 117brings the end of the cam 160 into contact with an operating member 212of the microswitch 207.

Operation of the microswitch 207 maintains the pistoncylinder 162pressurized to keep the upper surface of the fingers 117 in abutmentwith the connecting portion 22 of the now expanded U-shaped segments2012. Operation 10 of the microswitch 207 also pressurizes thepiston-cylinder 204 to move the hammers 208 down.

Such downward movement of the hammers 208 contacts the ends 21 of thesegments 20b with the surfaces 210 thereof and then bends these ends 21against the board 31. The still stationary fingers 117 prevent thesegments 20b from being pushed downwardly by the hammers 208.

Full downward movement of the hammers 208 causes the contact by a pin213 fixed to the driver 200 of the operating member 214 of a microswitch217. Such operation of the microswitch 217 depressurizes thepiston-cylinders 162 and 204.

Depressurization of the piston-cylinder 162 lowers fully the fingers117. Depressurization of the piston-cylinder 204 fully raises thehammers 208.

Operation of the microswitch 217 may also operate a motive source (notshown) to unclamp the board 31 and feed the board 31 out of the secondstation 27. Alternatively, the shaft 182 may be rotated by handoperation of the crank 184 and the board 31 may be similarly removed.

A reset button 218 may be operated to pressurize the piston-cylinder 148which moves the shuttle back to the first station 19 after manualremoval of the board 31. Alternatively, operation of the microswitch 217may effect such shuttle movement after the unclamping and removal of theboard 31.

Movement of the shuttle 90 to the first station 19 operates amicroswitch 219. Operation of the microswitch 219 initiatespressurization of the piston-cylinder 58.

Operation A single exemplary cycle of operation will now be described.

The reset button 218 is pushed to pressurize the pistoncylinder 148.Such pressurization ensures placement of the shuttle 90 at the firststation 19.

A number of supply reels 13 have been previously loaded into the cage 45to yield the same number of lengths of the wire stock 10 as the numberof the connectors 11 to be fabricated. The reset cams 83 are adjusted tofeed the proper predetermined lengths of the stock into the firststation 19.

Movement of the shuttle 90 operates the micro-switch 219 whichpressurizes the piston-cylinder 58 to move the feed block 53 of thefeeder 14. Such movement of the feed block 53 feeds the predeterminedlengths of the wire stock into the first station 19 over the shuttle 90.

Movement of the feed block 53 ultimately operates the microswitch 81.Operation of the microswitch '81 depressurizes the piston-cylinder 58 toreturn the feed block 53 to the left '(FIG. 4). Moreover, such operationof the microswitch 81 pressurizes the piston-cylinder 100.

Pressurization of the piston-cylinder moves the driver 97 down to firstoperate the cutter 87 and then the staple shaper 88, ultimatelyresulting in the formation of a plurality of U-shaped segments 20b inthe recesses 118. Also, full downward movement of the driver 97 operates.the microswitch 137.

Operation of the microswitch 137 first pressurizes the piston-cyinder131 and then depressurizes the piston-cylinder 100. Pressurization ofthe piston-cylinder 131 moves the retainer 129 fully down to ensureretention of the U- shaped segments 20b in the recesses 118 duringwithdrawal of the bender 88. Depressurization of the pistoncylinder 100withdraws the bender 88.

Full downward movement of the retainer 129 operates the microswitch 138to first depressurize the piston-cylinder 131 and then depressurize thepiston-cylinder 148.

Depressurization of the piston-cylinder 131 raises the retainer 129 outof interference with the shuttle 90. Depressurization of thepiston-cylinder 148 moves the staple-laden shuttle 90 to the secondstation 27.

After the board 31 is clamped by the clamp 152, the

start button 211 is pushed to pressurize the piston-cylinder 162.Pressurization of the piston-cylinder 162 moves the driving memberoperating device 151 to insert the staples 20b into the holes 23 and 24and to form the ends 21 thereof outwardly by the shoes 28.

At the desired insertion of the staples 20b, that is, with or withoutformation of the space 41, the microswitch 207 is operated. Operation ofthe microswitch 207 both holds the piston-cylinder 1-62 pressurized andpressurizes the piston-cylinder 204.

Holding the piston-cylinder 162 pressurized ensures that the fingers 117remain solidly in place. Pressurization of the piston-cylinder 204operates the final former 29 to clinch the segments 20b to the board 31and to extend one of the ends 21 thereof beyond the board 31.

Clinching of the segments 20]] operates the microswitch 217. Operationof the microswitch 217 depressurizes the piston-cylinders 162 and 204.

Depressurization of the piston-cylinder 162 allows full retraction ofthe fingers 117 into the shuttle 90 by the springs 168. Depressurizationof the piston-cylinder 204 moves the former 153 up.

After the board 31 with the connectors 11 thereon is removed from theclamp 152, the reset button 218 may again be pushed.

It is to be understood by those skilled in the art that theabove-described embodiments of the invention are merely illustrative andthat many modifications may be made within the scope and spirit of theinvention. For example, one or more of the connectors 11 may besimultaneously fabricated having extending ends 21 of any length.Moreover sources of motive power other than the piston-cylinder andmicroswitch arrangement may be utilized; or some of the motive power maybe supplied manually.

What is claimed is:

1. Fabricating apparatus for attaching a wire connector to an articlehaving at least one pair of holes therethrough, which apparatuscomprises:

a first station including, cutting means for producing at least onestraight wire segment of a predetermined length from a supply of wirestock, and

means for bending said straight wire segment into a 'U-shape, and

a second station including, means for inserting respectively the ends ofsaid bent segment into said holes so that said ends protrude beyond saidarticle, and

means for sequentially forming said protruding ends to simultaneouslyclinch said bent segment to said article and extend one of saidprotruding ends beyond the periphery of said article.

2. Fabricating apparatus as set forth in claim 1 wherein said formingmeans forms said protruding ends oppositely away from each otherparallel to an imaginary line drawn perpendicularly to an edge of saidarticle.

3. Fabricating apparatus according to claim 1 wherein said bending,inserting and forming means include:

a shuttle selectively reciprocable between said bending means at a firststation and both said inserting and forming means at a second station,said shuttle including:

a recess having side walls and a bottom wall, said bottom wall beingdefined by a selectively movable finger, said finger being stationary atsaid first station to act as a support for a connecting portion of saidU-shaped, bent wire segment, and

means for moving said finger at said second station to insert said endsof said bent segment into said holes and to support said insertedsegment during operation of said sequential forming means.

4. Fabricating apparatus according to claim 1 wherein said sequentialforming means includes:

a stationary preforming shoe for expanding the U-shape 12 of said bentsegment during the insertion thereof by said inserting means, and

a pair of movable hammers for clinching the ends of said expandedU-shaped bent segment to said article.

5. Fabricating apparatus according to claim 1 wherein said bending meansincludes:

a shuttle selectively movable between said first and second stations andhaving a recess therein,

a retainer having a shoulder selectively movable to overlie said recessby an amount equal to the diameter of said wire segment,

a finger for pushing said straight wire segment into said recess to bendsaid segment into said U-shape,

means for pushing said finger into said recess and then for removingsaid finger from said recess, and

means responsive to said pushing for moving said retainer to engage oneend of said U-shaped bent segment with said shoulder during said fingerremoval thus retaining said bent segment in said recess.

6. Fabricating apparatus according to claim 1 wherein said sequentialforming means includes:

a shuttle selectively movable between said first and second stations andhaving a recess therein, said recess retaining said U-shaped bentsegment after operation of said bending means,

a plate having therein a slot which overlies said recess,

and

a preforming shoe overlying said holes in said article,

said shoe being mounted within said slot and expanding the ends of saidbent segment during operation of said inserting means.

7. Apparatus for attaching a wire connector to an article having a pairof holes therethrough, which apparatus comprises:

a first bending station,

a second inserting and forming station,

a shuttle selectively reciprocable between said stations,

first means responsive to reciprocation of said shuttle to said firststation for sequentially placing a straight wire segment of apredetermined length on said shuttle,

pushing said segment into a recess in said shuttle and simultaneouslybending said segment into a U-shape, and then reciprocating said shuttleto said second station,

second means responsive to reciprocation of said shuttle to said secondstation for sequentially clamping said article,

inserting respectively the ends of said U-shaped bent segment into saidholes from said recess, and then forming sequentially said inserted endsboth to clinch said segment to said article and to extend one of saidprotruding ends beyond the periphery of said article, and

third means for reciprocating said shuttle to said first station.

8. Apparatus for attaching a wire connector to an article having a pairof holes therethrough, which apparatus comprises:

a first bending station,

a second inserting and forming station,

a shuttle selectively reciprocable between said stations,

first means responsive to reciprocation of said shuttle to said firststation for sequentially feeding wire stock onto said shuttle,

severing said wire stock to produce a straight wire segment of apredetermined length on said shuttle,

pushing said segment into a recess in said shuttle and simultaneouslybending said segment into a U-shape, and then reciprocating said shuttleto said second station,

normally unoperated second means within said shuttle fourth means forreciprocating said shuttle to said first station.

References Cited UNITED STATES PATENTS Cardani 2279l Gagnon.

Rogers 14071 X Stuhre 2934 Lenders.

Durr et al.

Pedersen et a1.

THOMAS H. EAGER, Primary Examiner.

U.S. Cl. X.R.

